Adjustable valve poppet

ABSTRACT

A valve arrangement having a valve body with an inlet passage and an outlet passage. A valve seat is disposed in the valve body and forms an aperture positioned in the path of fluid flow between the inlet and outlet passages. A shaft member is disposed within the valve body and has a flow control member connected to the end of the shaft. The flow control member has a valve portion for operably engaging the valve seat and a valve extension portion that extends from the valve portion and circumscribes the shaft in order to shield the shaft from being exposed to contaminants. The valve portion and valve extension portion are integrally formed into a one-piece member thus eliminating an additional component in the valve design.

FIELD OF THE INVENTION

The present invention relates to a one-piece valve arrangement and method of assembly of the valve arrangement in order to maintain proper alignment of the valve member with the valve seat during assembly.

BACKGROUND OF THE INVENTION

Poppet style valves are well known and used in controlling the flow of fluids and especially gasses through a valve body. For example, the recirculation of a portion of the exhaust stream of an internal combustion engine into the intake manifold can be accomplished using a poppet style exhaust gas recirculation (EGR) valve. One obstacle with using valves of any type in an EGR application is that the valve member will almost certainly be exposed to moisture laden corrosive vapor that can adhere to and cause coking on the valve shaft. Sometimes the coking materials can enter into the actuator housing by seeping through the bushing between the valve shaft and actuator as the valve shaft moves in an axial direction. This can cause unwanted corrosion of the actuator.

In order to prevent the exposure of the valve shaft to contaminants some valves have been designed to incorporate certain anti-contamination features that will direct the corrosive gasses away from the valve shaft during valve operation. The use of anti-contamination features increases the number of parts that must be arranged during assembly. Additionally, the use of anti-contamination features can also effect the alignment of the valve member with regard to the valve seat since the use of such items as shaft shields, scrapers and other features make it more difficult to align the valve member with the valve seat during assembly.

SUMMARY OF THE INVENTION

The present invention relates to a valve arrangement having a valve body with an inlet passage and an outlet passage. A valve seat is disposed in the valve body and forms an aperture positioned in the path of fluid flow between the inlet and outlet passages. A shaft member is disposed within the valve body and has a flow control member connected to the end of the shaft. The flow control member has a valve portion for operably engaging the valve seat and a valve extension portion that extends from the valve portion and circumscribes the shaft in order to shield the shaft from being exposed to contaminants. The valve portion and valve extension portion are integrally formed into a one-piece member thus eliminating an additional component in the valve design.

The present invention also includes a method of assembling a valve while maintaining alignment of the valve member with respect to the valve seat during assembly. The valve member has a housing with an inlet port and an outlet port. A valve seat is arranged in the housing in the path of fluid flow between the inlet and outlet ports. A flow control member having a valve portion has an axial aperture formed through the valve member for receiving an end of a valve shaft. The method of aligning includes placing the flow control member against the valve seat, sliding one end of the valve shaft into the aperture of the flow control member, adjusting the position of the valve shaft to a predetermined position in order to allow proper valve function and fixing the valve shaft to the flow control member once proper alignment has been set.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a cross-sectional plan view of the valve housing with the one-piece flow control member inserted and aligned with the valve seat and having the valve shaft located outside of the valve body prior to insertion;

FIG. 2 is a cross-sectional plan view of the flow control member positioned in alignment with the valve seat having the valve shaft connected to the flow control member after alignment;

FIG. 3 is a close up cross-sectional plan view of the flow control member seated on the valve seat with the end of the valve shaft inserted through the aperture of the flow control member during alignment; and

FIG. 4 is a cross-sectional plan view of an alternate embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

FIGS. 1-3 show a valve arrangement 10 that incorporates a one piece flow control member 22 and depicts a method of aligning the flow control member 22 during assembly of the valve arrangement 10. The valve arrangement 10 includes a valve body 12 having an inlet port 14 and an outlet port 16. The valve body 12 defines the path of fluid flow between the inlet port 14 and the outlet port 16. The fluid flowing through the valve body 12 can be any type of fluid medium where a valve incorporating a flow control member 22 can be used. This particular embodiment of the invention depicts a valve body 12 that is part of an exhaust gas recirculation (EGR) valve member and the fluid medium flowing through the valve body 12 is exhaust gas from the engine exhaust manifold that is recirculated back to the intake manifold of the engine. A valve seat 18 having an aperture 20 is contained within the valve body 12 and is positioned in the path of fluid flow between the inlet port 14 and outlet port 16. The valve seat 18 can be a separate piece that is press fit into the valve body 12 or it may be cast or integrally formed within the valve body 12.

The flow control member 22 is configured to selectively engage with the valve seat 18 in order to seal off the aperture 20 and block the flow of fluid between the inlet port 14 and outlet port 16. The flow control member 22 is an integrally formed one piece member having a valve portion 24, that is a surface configured to mate with and seal against the valve seat 18. The flow control member 22 also has a valve extension 26 that extends from the valve portion 24 and is defined as the portion of the flow control member 22 that extends beyond that which is necessary to facilitate the opening and closing of the valve seat 18.

The valve extension portion 26 is shown in the drawings as being an annular wall that circumvents a portion of a valve shaft 30. However, the valve extension portion 26 does not necessarily have to be an annular wall that circumvents a portion or the valve shaft 30; rather it can take many forms and does not have to extend a great distance from the valve portion 24. The valve extension portion 24 can provide many benefits such as coking and or flow deflection. In the present embodiment of the invention the valve extension portion 26 functions to protect the valve shaft 30 from coming into direct contact with the fluid medium moving through the aperture 20 of the valve seat 18 from the inlet port 14. By preventing contact- of fluid medium with the valve shaft 30 there is a significant reduction in the occurrence of coke formation on the valve shaft 30.

The flow control member 22 also has a stem 28 formed generally about the longitudinal axis of the valve shaft 30. The stem 28 shown in FIGS. 1-2 have an open end, while FIG. 3 is slightly different in that the stem 28 has a closed end 35 and forms a blind hole. The valve shaft 30 has a moveable end 32 that is configured to slide into the stem 28. A radial groove 34 is formed on the surface of the valve shaft 30 near the moveable end 32. The radial groove 34 is also configured to slide within the stem 28. The valve shaft 30 is then connected to the flow control member 22 by forming a crimp 38 in the stem 28, so that the stem 28 has a crimp 38 formed at the location of the radial groove 34 on the valve shaft 30. Once the crimp 38 has been formed the flow control member 22 will move longitudinally with the sliding movement of the valve shaft 30 to open and close aperture 20 of the valve seat 18.

FIGS. 1-3 depict a method for aligning the flow control member 22 during assembly of the valve arrangement 10 so that the valve portion 24 will properly seat against the valve seat 18 to ensure proper valve operation. FIG. 1 depicts the first step of placing the flow control member 22 in position against the valve seat 18. While FIG. 1 depicts the flow control member 22 being placed against the valve seat 18 it is within the scope of this invention for the flow control member 22 to be placed at any predetermined position relative to the valve seat. The flow control member 22 is positioned so that the stem 28 extends through the aperture 20 of the valve seat 18. The moveable end 32 of the valve shaft 30 is then slid into position so that the moveable end 32 enters the stem 28. FIG. 2 shows the valve shaft being placed in position. Aligning the valve shaft 30 also involves inserting bushing 40 to the proper depth in the valve body 12. Achieving proper alignment of the valve shaft and bushing 40 eliminates the need to use shims or other spatial compensating components. Once alignment has been achieved the stem 28 is crimped 38 to connect the flow control member 22 to the valve shaft 30.

FIG. 3 shows the point of connection between the shield valve 22 and the valve shaft 30. FIG. 1 as depicted is slightly different from FIG. 2 in that the stem 28 has a closed end or blind hole that the valve shaft 30 slides into. This will ensure that there can be no leakage through the valve seat 18 by way of the connection point between the stem 28 and valve shaft 30. The crimp 38 that hold the flow control member 22 to the valve shaft 30 is formed at the radial groove 34. It is also within the scope of this invention to fasten the flow control member 22 to the valve shaft 30 by a means other than the crimp 38. For example, adhesives, soldering or laser welding can be used to connect the valve shaft 30 to the flow control member 22. FIG. 3 shows a close-up view of the radial groove 34 at the formation of the crimp 38. Knurled portions 36 on the moveable end 32 of the valve shaft 30 are placed adjacent the radial groove 34. The knurled portions 36 function during the step of sliding the valve shaft 30 into the stem 28 by preventing unwanted movement of the valve shaft 30 during assembly.

The flow control member 22 is not necessarily placed relative to the valve seat, rather the predetermined position can be in relation to a specific flow position, or a full open stop, or in relation to a valve mounting surface feature. The reason for this is that the flow control member 22, valve shaft 30 and a bushing 40 may be supplied independent from the valve body 12. For example, the valve body 12 may be integrally formed as part of another component such as a turbocharger housing and an engine intake manifold. The flow control member 22 valve stem 30 and bushing 40 may be connected to an actuator (not shown) that is fastened to the valve body 12. It is possible to pre-configure the flow control member 22 based on the mounting surface between the valve body 12 and the actuator (not shown) that controls the position of the flow control member 22.

FIG. 4 depicts an alternate embodiment of a valve arrangement 100. This particular embodiment of the invention has a flow control member 102 that has a slightly modified configuration. The flow control member 102 has a stem 104 that does not extend into the aperture 20 of the valve seat 18. The valve seat 18 is closed by an annular shoulder 106 that rests against the surface of the valve seat 18. The stem 104 is used to connect the flow control member 102 with the valve shaft 30 in a manner similar to the embodiment of the invention described in FIGS. 1-3. That is the end of the valve shaft 30 slides into the stem 104 and the crimp 34 is formed in between the stem 104 and the valve shaft 30. The crimp 34 connects the flow control member 102 with the valve shaft 30 so that the flow control member 102 moves with the valve shaft during operation of the valve arrangement 100.

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. 

1. A valve arrangement comprising: a valve body having an inlet passage and an outlet passage; a valve seat disposed in said valve body and having an aperture positioned in the path of fluid flow between said inlet and outlet passages; a shaft disposed in said valve body; a flow control member connected to said shaft and having a valve portion for operably engaging said valve seat and a valve extension portion extending from said valve portion wherein said valve extension portion deflects fluid flowing through said valve seat away from said shaft and circumscribes said shaft, wherein said valve portion and said valve extension portion are an integrally formed one piece member.
 2. The valve arrangement of claim 1 further comprising: a moveable end of said valve shaft capable of sliding axially along the axis of said valve shaft; a stem formed on said flow control member, wherein said stem is configured to receive and connect to said moveable end of said valve shaft.
 3. The valve arrangement of claim 2 wherein said stem is connected to said moveable end by crimping.
 4. The valve arrangement of claim 3 further comprising: a radial groove circumscribing said valve shaft, wherein said stem is crimped into said radial groove.
 5. The valve arrangement of claim 2 wherein said moveable end of said valve shaft has a knurled portion that enters said stem.
 6. The valve arrangement of claim 2 wherein said stem can be closed or open ended.
 7. The valve arrangement of claim 1 further comprising a radial groove circumscribing said valve shaft, wherein said flow control member is connected to said valve shaft at said radial groove.
 8. The valve arrangement of claim 1 wherein said flow control member is connected to said valve shaft by an aperture formed in said flow control member configured to slidably receive an end of said valve shaft, wherein said valve shaft and said flow control member are then connected by crimping a portion of said flow control member to said valve shaft.
 9. The valve arrangement of 8 wherein said valve shaft and said valve member are connected using one of the following, adhesive, soldering, crimping or laser welding.
 10. A valve arrangement comprising: a valve seat forming an aperture in the path of fluid flow through an exhaust gas recirculation valve; a shaft having a moveable end capable of sliding along the axis of said valve shaft; a flow control member connected to said moveable end of said valve shaft having a valve portion configured to selectively engage said valve seat and a valve extension portion extending from said valve portion; and a stem formed in said flow control member, wherein said stem is configured to slidingly receive and fasten to said moveable end of said valve shaft.
 11. The valve arrangement of claim 10 further comprising a radial groove portion circumscribing said valve shaft near said moveable end of said valve shaft, wherein said flow control member is fastened to said valve shaft by crimping said stem into said radial groove.
 12. The valve arrangement of claim 10 wherein said valve stem extends away from said aperture of said valve seat, and said valve stem is configured to slidably receive and fasten to said moveable end of said valve shaft.
 13. The valve arrangement of claim 10 wherein said valve portion is an annular shoulder that contacts said valve seat.
 14. The valve arrangement of claim 10 wherein said stem can form an open or blind hole through said flow control member.
 15. The valve arrangement of claim 10 wherein said stem protrudes into said aperture of said valve seat.
 16. A method of assembling a valve while maintaining alignment of said valve having a valve housing, an inlet port, an outlet port, a valve seat arranged in said housing in the path of fluid flow between said inlet port and said outlet port, flow control member operably disposed in relation to said valve seat, wherein said flow control member has an integrated valve extension portion with an aperture formed in said flow control member; a valve shaft having an end configured to slide axially into said aperture comprising the steps of: placing said flow control member in a predetermined position; sliding said end of said valve shaft into said aperture of said flow control member so said valve extension portion circumscribes said valve shaft; adjusting the position of said end of said valve shaft in relation to said stem to a predetermined position in order to allow proper valve function; and fixing said valve shaft to said flow control member.
 17. The method of claim 16 wherein said predetermined position is in relation to said valve seat, or a specific flow position, or a full open stop or in relation to a valve mounting surface feature.
 18. The method of claim 16 wherein the step of fixing said flow control member to said valve shaft is accomplished by crimping a portion of said flow control member to said valve shaft.
 19. The method of claim 16 further comprising the steps of: providing a stem on said shaft shield where said axial aperture is located; and providing a radial groove near said end of said shaft, wherein said step of fixing is accomplished by crimping said stem into said annular groove.
 20. The method of claim 16 further comprising: providing a knurled surface of said valve shaft adjacent said radial groove, wherein said knurled portion holds said end of shaft in position until said step of fixing occurs. 